APPLICATION EDGE VOLUME 1, ISSUE 4
COOLING LARGE VARIABLE FREQUENCY DRIVES
Medium-voltage variable frequency drives (VFD) are
available in power ranges from 200 to 100,000 kW.
High efficiency over a wide speed range, ease of
installation, low maintenance and other factors have
contributed to increased application of VFDs. Small
VFDs (200–5000 HP) are typically air-cooled. As power
ratings increase above 5000 HP, liquid cooling is more
common because air cooling is not as economical,
and liquid cooling reduces the footprint of these
higher power drives (see Figure 1).
Figure 1. Power vs. voltage for air- and liquid-cooled VFDs
Sources of Heat in a VFD System
Figure 2 shows the basic building blocks of a VFD and
motor system. All building blocks shown below are
not necessarily needed for every system.
Figure 2. Basic building blocks of VFD system
As shown in Figure 2, the major sources of heat in a
VFD are:
1. Input isolation transformer
2. AC-to-DC Converter
3. DC Link (energy storage)
4. DC-to-AC Inverter
The heat contribution by the converter and inverter
sections is approximately 75% of the VFD system heat
loss. Typically the VFD system itself is 96–97% efficient.
The input isolation transformer is typically 98–99%
efficient. VFDs that permit component splitting may
offer more packaging and cooling alternatives — for
example, being able to locate the input transformer
separately (or outdoors) from the VFD.
Drive Cooling
In performing its critical operation, a well-selected
VFD cooling system provides three major functions:
1. Reliably removes the heat from the power
semiconductor devices in the inverter, converter,
and from their auxiliary components.
2. Maintains the overall VFD temperature for long
system life.
3. When optimized, allows the VFD to deliver rated
power with the smallest equipment footprint.
At the present time, there are two methods of cooling
a variable frequency drive, air cooling and liquid
cooling.
Air-Cooled Variable Frequency Drive
VFD air-cooling works on the principle that heat
transfers from hot devices and component surfaces
to the mass of air flowing over or past them. Most
air-cooled VFDs use fans to force air through the VFD
to dissipate heat. Figure 3 shows a front view of an
air-cooled VFD.
Warm Air Exhaust
Cooling Air In
Figure 3. Typical air-cooled VFDs and air flow
Advantages
Air cooling of VFDs is simpler than liquid cooling and
has the following advantages:
1. An air-cooled VFD cooling system is self-contained.
There are no pumps, hoses, piping, filters,
deionizers, or heat exchangers.
2. Servicing/support of the client’s HVAC system is
more readily available.
3. When applied for starting duty only, smaller VFDs
can often be applied to large motors on a short
time rating.
Disadvantages
Corresponding disadvantages of an air-cooled VFD
include:
1. Air-cooled units usually have a larger footprint
compared to a similar size liquid-cooled VFD.
2. Blower fans for cooling the VFD typically have
noise levels of 79–82 dB(A) at 1 meter from drive.
3. The VFD area must be kept clean, dry and free of
dust. Inspection and maintenance of air filters
may be required.
4. HVAC power requirements for cooling the heated
air rejected from the drive may be higher than the
pumping power required for liquid-cooled VFDs.
This should be considered when doing life cycle
cost analysis.
Maintenance
Major maintenance items on air-cooled VFDs include:
1. Inspection and cleaning of air filters. In most
VFDs, this can be done during operation.
2. Inspection and verification of the HVAC operation
for proper cooling, dust or contaminants buildup,
and other visible problems.
3. Verify that the VFD location continues to maintain
an atmosphere free from dust, moisture and
humidity.
Liquid-Cooled Variable Frequency Drive
Liquid-cooled VFD cooling systems are more complex
than their air-cooled VFD counterparts. Liquid-
cooled systems are engineered for the installation,
considering temperature ambient(s), cooling water
availability and redundancy level required.
Principles of Liquid-Cooling
Liquid-cooled VFDs include a pump cooling panel
consisting of electronic controls, electrical pumps and
mechanical equipment to move the liquid through the
VFD. This pump cooling panel has a similar role as
the industrial fans that draw air into and through air-
cooled VFDs. The liquid used in most VFDs is either
deionized water or a mixture of deionized water and
glycol for low ambient temperature applications. The
deionization is required to maintain a low electrical
conductivity of the fluid, a requirement imposed by
the high voltages that appear on the heat-producing
components.
Liquid-Cooling Systems Configurations
There are two major configurations of VFD liquid
cooling systems shown in Figure 4.
1. Liquid-cooled VFDs that have an internal
liquid-to-liquid heat exchanger, Figure 4a.
2. Liquid-cooled VFDs that are outfitted with
an outdoor liquid-to-air heat exchanger for heat
dissipation, Figure 4b.
Figure 4a.
Figure 4b.
Figure 4. VFD liquid cooling system configurations
In the liquid-to-liquid system, Figure 4a, the cooling
loop “A” is always a closed loop carrying deionized
fluid internal to the VFD through a liquid-to-liquid heat
exchanger. The second liquid cooling loop (Loop B)
carries the plant cooling water, which takes away the
heat picked up from the internal exchanger.
In the liquid-to-air system, Figure 4b, the cooling
loop “A” and the cooling loop “B” are actually one
common loop carrying deionized fluid. The fluid
path passes through the hot drive parts, through the
pump panel and out to the external liquid-to-air heat
exchanger where it is cooled and returned. Because
the heat exchanger is often located outdoors, the
cooling fluid must be tolerant of the outdoor ambient
temperatures. The fluid may need to include a glycol
mixture with the water to inhibit freezing.
Cooling System Arrangement Details
Liquid-cooled VFDs as shown in Figure 4a are fitted
with an internal liquid-to-liquid heat exchanger. The
two cooling loops in the system are the VFD loop
(Loop A), which is the deionized liquid loop, and
the plant liquid loop (Loop B). A specific plant liquid
VFD inlet temperature range is required for optimum
heat transfer by the cooling system. Liquid-to-liquid
systems are less expensive than liquid-to-air systems
and more compact. However, liquid-to-liquid systems
do require facility cooling water to be brought to the
VFD. They are best applied at sites where cooling
water is also used to cool other plant processes.

As shown in Figure 4b, VFDs with liquid-to-air heat

exchangers typically use outdoor radiator type
forced air-cooled exchangers to transfer the heat
from the liquid. This is a similar arrangement to a car
radiator. One of the benefits is that no plant cooling
liquid is required to cool the VFD, making it a very
attractive solution for remote VFDs or facilities with
no available cooling water. Liquid-to-air systems are
more expensive than liquid-to-liquid designs. The
higher costs include the exchanger itself, the space
and mounting pad for the exchanger, piping and the
ongoing expense of the fan operation. Operation
depends on the outdoor ambient temperature
being cool enough to transfer the heat efficiently.
Figure 5a. VFD liquid-to-liquid cooling system
In practice, ambient temperatures of up to 40°C can
easily be accommodated by this type of system —
higher ambient temperatures may require de-rating
of the VFD.

Liquid-Cooled VFD Components, System Details

and Functions

VFD cooling systems typically include the following

equipment and instrumentation:
1. Motor driven pumps
2. Control system with instrumentation and sensors
for conductivity, temperature, pressure and flow
3. Coolant reservoir
4. Heat exchanger
5. Deionizer cartridge and filter
6. Pipes, valves, and actuators

Figures 5a and 5b show typical liquid cooling system

process and instrumentation diagrams. This may vary
from manufacturer to manufacturer, and even from
drive to drive for a particular manufacturer. However,
the general concept remains the same.

Liquid is passed through the components at various

points within the drive that are in contact with the
power semiconductors, diodes and other heat-
generating devices. As the VFD delivers power, heat
is transferred from the devices to the hot surfaces and
then to the liquid flowing through the pump. Then
this hot liquid is pumped from the VFD through the
heat exchanger. Depending on the selection, heat
from the hot liquid is either transferred to the plant
cooling water as shown in Figure 5a, or to the air
Figure 5b. VFD liquid-to-air cooling system
as shown in Figure 5b. The cooled liquid then flows
back to the VFD and the whole process is repeated.
Approximately 90% of the heat generated by the VFD
is cooled by the liquid, and 10% of the heat is still
transferred to the air.
Since the VFD cooling loop liquid must be deionized,
a small amount of liquid is always passed through
a deionizer DI-resin bed. This maintains the
required ultra-low conductivity of the water. Several
parameters such as liquid temperature, conductivity
and flow are monitored at all times.
Each pump shown in Figures 5a and 5b is sized
for 100% full load capacity, enabling the VFD to
continue running even if one of the pumps is out of
operation. The entire pumping process is managed
by a programmable logic controller that is user
configurable.
Typical liquid temperatures in the VFD are between
40°C and 52°C, and flow rate ranges from 100 to 700
liters/minute.
Comparative Selection Points of Air-Cooled versus
Liquid-Cooled VFDs
In every VFD application, the goal is to minimize
initial cost, including installation, and to maximize
process payback and energy savings. Knowing the
environment in which the VFD will be located, motor
power requirements, and the type of load to be driven
are key items in accomplishing these goals.
Figure 6 combines these elements into a decision chart.
Individual user preference and changing technology
affect this selection, as was described earlier.

Advantages of Liquid-Cooled Systems

1. Liquid-cooled VFDs are designed to dissipate the
high levels of heat typical of larger VFDs.
2. A liquid-cooled VFD footprint is smaller than
equivalent air-cooled system per kilowatt of
delivered power, resulting in lower building and
real estate costs.
3. Reduced exposure to airborne pollution gives
higher environmental tolerance.
4. HVAC costs are considerably lower compared to
an air-cooled VFD of the same power output.

Disadvantages of Liquid-Cooled Systems

While the advantages with a liquid-cooled system
often outweigh the disadvantages, there are some
limitations:
1. For installations with an outdoor air-cooled heat-
exchanger, fan noise can be high and may require
sound barriers or special fans to mitigate the noise.
Typical fan noise is about 85 dB(A) at 1 meter.
2. Liquid temperature, resistivity and flow must be
monitored and controlled at all times.
3. Filter and deionizer cartridges typically need to be
Figure 6. Flowchart on selecting air-cooled vs. liquid-cooled VFD
replaced every 5 years or when depleted.
4. 10–15% of the VFD heat loss is still dissipated into
the electrical room, requiring a corresponding Conclusion
level of HVAC. This article presented the details of VFD cooling
systems and why they are a critical consideration
Maintenance during the engineering and design stages of a project.
Important maintenance tasks on liquid-cooled One of the key recommendations is that careful
VFDs include: evaluation of each VFD application be made across
1. Inspect and replace the deionizer cartridge as a range of parameters such as safety, reliability,
needed. A resistivity meter in the cooling system maintainability, and life cycle costs. This will allow the
normally provides advance indication the best decision of air versus liquid cooling.
deionizer needs servicing.
2. Inspect pumps, cooling fans and motors.

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